Smithco Sand Star IV Owner's manual

Sand Star IV

Model 45-204

3WD-Series Parallel

Hydraulic Steering

sn: 4HS0200

July 2016

Product Support: Hwy SS & Poplar Ave; Cameron WI 54822

1-800-891-9435 productsupport@smithco.com

Parts & Service

Introduction Service Diagrams Parts Accessories Reference

CONTENTS

Introduction �� 1-3

Introduction �� 1

Safe Practices �� 2

Specications �� 3

Service �� 4-11

Maintenance �� 4-6

Service Chart �� 7

End User’s Service Chart �� 8

Adjustments �� 9-10

Storage ��11

Diagrams �� 12-15

Wiring Diagram �� 12-13

Hydraulic Diagram �� 14-15

Parts �� 16-49

Main Frame �� 16-17

Seat Panel �� 18-19

Front Fork �� 20-21

Dashboard �� 22-23

Foot Pedal Linkage �� 24-25

Fuel Tank �� 26-27

Oil Tank �� 28-29

Belts and Pulleys �� 30-31

18 HP Engine �� 32-33

Pump �� 34-35

Rear Axle �� 36-37

Rear Rake Lift �� 38-39

Center Lift �� 40

13-729 Valve �� 41

34-103 Orbitrol �� 42-43

Rear Wheel Motors �� 44-45

42-797 Variable Pump �� 46-47

Decals �� 48

Quick Reference �� 49

Accessories �� 50-55

Roll Bars �� 50-51

Light Kit �� 52-53

Air Cleaner Kit �� 54-55

Attachments �� A-B-C

Warranty ��

1

Introduction

INTRODUCTION

Thank you for purchasing a Smithco product�

Read this manual and all other manuals pertaining to the Bunker Rake carefully as they contain safety, oper-

ating, assembly and maintenance instructions� Failure to do so could result in personal injury or equipment

damage�

Keep manuals in a safe place after operator and maintenance personnel have read them� Right and left sides

are from the operator’s seat, facing forward�

All Smithco machines have a Serial Number and Model Number� Both numbers are needed when ordering

parts� Refer to engine manual for placement of engine serial number�

For product and accessory information, help nding a dealer, or to register your product please contact us at

www�Smithco�com�

Information needed when ordering replacement parts:

1� Model Number of machine

2� Serial Number of machine

3� Name and Part Number of part

4� Quantity of parts

For easy access record your Serial and Model numbers here�





WARNING

Failure to follow cautious operating practices can re-

sult in serious injury to the operator or other persons.

The owner must understand these instructions, and

must allow only trained persons who understand these

instructions to operate this vehicle.

WARNING:

Engine exhaust and some of its constituents are

known to the State of California to cause cancer,

birth defects, and other reproductive harm�

For more information visit

www.P65Warning.ca.gov

2

Introduction

SAFE PRACTICES

1� It is your responsibility to read this manual and all publications associated with this machine (engine,

accessories and attachments)�

2� Never allow anyone to operate or service the machine or its attachments without proper training and

instructions� Never allow minors to operate any equipment�

3� Learn the proper use of the machine, the location and purpose of all the controls and gauges before

you operate the equipment� Working with unfamiliar equipment can lead to accidents�

4� Wear all the necessary protective clothing and personal safety devises to protect your head, eyes, ears,

hands and feet. Operate the machine only in daylight or in good articial light.

5� Inspect the area where the equipment will be used� Beware of overhead obstructions and underground

obstacles� Stay alert for hidden hazards�

6� Never operate equipment that is not in perfect working order or without decals, guards, shields, or other

protective devices in place�

7� Never disconnect or bypass any switch�

8� Carbon monoxide in the exhaust fumes can be fatal when inhaled, never operate a machine without

proper ventilation�

9. Fuel is highly ammable, handle with care.

10� Keep engine clean� Allow the engine to cool before storing and always remove the ignition key�

11� After engine has started, machine must not move� If movement is evident, the neutral mechanism is not

adjusted correctly. Shut engine o and readjust so the machine does not move when in neutral position.

13. Never use your hands to search for oil leaks. Hydraulic uid under pressure can penetrate the skin and

cause serious injury�

14� This machine demands your attention� To prevent loss of control or tipping of the vehicle:

A� Use extra caution in backing up the vehicle� Ensure area is clear�

B� Do not stop or start suddenly on any slope�

C� Reduce speed on slopes and in sharp turns� Use caution when changing directions on slopes�

D� Stay alert for holes in the terrain and other hidden hazards�

15� Before leaving operator’s position for any reason:

A� Disengage all drives�

B� Lower all attachments to the ground�

C. Shut engine o and remove the ignition key.

16� Keep hands, feet and clothing away from moving parts� Wait for all movement to stop before you clean,

adjust or service the machine�

17� Keep the area of operation clear of all bystanders�

18� Never carry passengers�

19� Stop engine before making repairs/adjustments or checking/adding oil to the crankcase�

20� Use parts and materials supplied by Smithco only� Do not modify any function or part�

These machines are intended for professional maintenance on golf courses, sports turf, and any other

area maintained turf and related trails, paths and lots. No guaranty as to the suitability for any task is

expressed or implied.

3

Introduction

SAND STAR SPECIFICATIONS

WEIGHTS AND DIMENSIONS

Length 68" (1�73 m)

Width 58" (1�47 m)

Height 52" (1�2 m)

Wheel Base 42" (1�07m)

Ground Clearance 5�5" - 7" (13 -18 cm) - under cultivator depending on attachment

Weight 3WD - 915 lbs� ( 415 kg)

SOUND LEVEL (EAR PROTECTION REQUIRED)

At Ear Level 87 dB

ENGINE

Make Briggs and Stratton Vanguard

Model# 356447

Type / Spec# 0263 G

Horsepower 18 hp (13 kW)

Fuel Unleaded 87 Octane Gasoline Minimum

Lubrication System Full Pressure

Alternator 16 amp

WHEELS & TIRE Three: 22 X 11 - 10�0 Knobby Tires 5 psi (�34 bar)

Optional: 23-10�50 x 12 Turf Tires 5 psi (�34 bar)Smithco # 48-265

SPEED

Forward Speed 0 to 10 m�p�h� (0-16 kph)

Reverse Speed 0 to 5 m�p�h� (0-8 kph)

BATTERY Automotive Type SP 35

BCI Group Size 35

Cold Cranking Amps 300

Ground Terminal Polarity Negative (-)

Maximum Length 7�5" (19 cm)

Maximum Width 5" (12,7 cm)

Maximum Height 7�5" (19 cm)

FLUID CAPACITY

Crankcase Oil See Engine Manual

Fuel 20 quarts (18�93 liters)

Hydraulic Fluid 20 quarts (18�93 liters)

Grade of Hydraulic Fluid SAE 10W-40 API Service SJ or higher Motor Oil

ROPS CERTIFICATION

Rops ISO 21299

Seatbelts OSHA 1928�51

4

Service

MAINTENANCE

Before servicing or making adjustments to machine, stop engine and remove

key from ignition�

Use all procedures and parts prescribed by the manufacturer's� Read the engine

manual�

LUBRICATION

Use No� 2 General purpose Lithium Base Grease and lubricate every 100 hours� The Sand Star has four

grease ttings. One located on the steering cylinder , two on the rake lift , on the rod end of the center lift

cylinder�

REMOTE AIR CLEANER

1� Un-clip the two clips, remove the cover and pull out the element�

2. To service, clean by tapping gently on at surface. Do not oil. Replace if very dirty or damaged.

3� Clean out the inside of the body and cover�

4� Place the element into the body and put the cover back on�

TOWING

When it is necessary to move the Sand Star without engine running, bypass valve built into hydrostatic pump

must be "open" by turning it counterclockwise� The valve is located on the right side of the pump� An "open"

valve allows uid to pass through the wheels freely. When normal, driven, operation is desired, valve should

be "closed by turning it clockwise� Failure to "close" the valve with engine running means no power to wheels�

The machine can be moved for a short distance with the engine o, but we do not recommend this as a

standard procedure� When towing do not tow the machine faster than 2-3 MPH (3-5 km/h) because the drive

system may be damaged� The tires may lock up if the machine is towed too fast� If this occurs, stop towing

the machine� If the machine must be moved a considerable distance, transport it on a truck or trailer�

5

Service

MAINTENANCE

TIRE PRESSURE

Caution must be used when inating a low tire to recommended pressure. Over inating can cause tires to

explode. Tires should be 5 psi (0.34 bar). Improper ination will reduce tire life considerably.

ENGINE

Change and add oil according to chart below. Do not overll. Use a high quality detergent oil classied "For

Service SJ or higher" SAE 30 oil� Use no special additives with recommended oils� Do not mix oil with gaso-

line�

SAE VISCOSITY GRADES

Starting Temperature Range Anticipated Before Next Oil Change 18-462-P

Use of multi-viscosity oils (10W-30, etc�) Above 80° F (27° C) will result in high oil consumption and possible

engine damage� Check oil level more frequently if using these types of oils�

SAE 30 oil, if used below 40° F (4° C), will result in hard starting and possible engine bore damage due to

inadequate lubrication�

HYDRAULIC OIL

1� Use SAE 10W-40 API Service SJ or higher motor oil�

2. For proper warranty, change oil every 500 hours or annually, which ever is rst and change lter after

the rst 50 hours, then every 250 hours thereafter.

3� The oil level should be 2" to 2

1

/

2

" from top of tank when uid is cold. Do not overll.

4. After changing oil and/or lter, run the machine for a few minutes. Check oil level and for leaks.

5. Always use caution when lling hydraulic oil tank or checking level to keep system free of contaminants.

Check and service more frequently when operating in extremely cold, hot or dusty conditions�

6. If natural color of uid is black or smells burnt, it is possible that an overheating problem exists.

7. If uid becomes milky, water contamination may be a problem.

8. If either of the above conditions happen, change oil and lter immediately after uid is cool and nd

cause� Take uid level readings when system is cold.

9� In extreme temperatures you can use straight weight oil� We recommend SAE 30W API Service SJ or

higher when hot (above 90°F (33°C)) and SAE 10W API Service SJ or higher when cold (below 32°F

(0°C) ambient temperature� Use either motor oil or hydraulic oil, but do not mix�

10� Oil being added to the system must be the same as what is already in the tank� Mark tank ll area as to

which type you put in�

6

Service

MAINTENANCE

WHEEL MOUNTING PROCEDURE

1. Turn machine o and remove key.

2� Block one of the other wheels�

3� Loosen nuts slightly on wheel to be removed�

4� Jack up machine being careful not to damage underside of machine�

5� Remove nuts� Remove wheel�

5� Place new wheel on hub lining up bolt holes�

6. Torque nuts to 64-74 ft/lb (87-100 Nm) using a cross pattern. Re-torque after rst 8 hours and every 250

hours thereafter�

7� Lower machine to ground and remove blocks and jack�

BATTERY

Batteries normally produce explosive gases which can cause personal injury. Do not allow ames, sparks or

any ignited object to come near the battery� When charging or working near battery, always shield your eyes

and always provide proper ventilation�

Battery cable should be disconnected before using "Fast Charge"�

Charge battery at 15 amps for 10 minutes or 7 amps for 30 minutes� Do not exceed the recommended

charging rate� If electrolyte starts boiling over, decrease charging�

Always remove grounded (-) battery clamp rst and replace it last. Avoid hazards by:

1� Filling batteries in well-ventilated areas�

2� Wear eye protection and rubber gloves�

3� Avoid breathing fumes when electrolyte is added�

4� Avoid spilling or dripping electrolyte�

Battery Electrolyte is an acidic solution and should be handled with care� If

electrolyte is splashed on any part of your body, ush all contact areas imme-

diately with liberal amounts of water� Get medical attention immediately�

JUMP STARTING

Use of booster battery and jumper cables� Particular care should be used when connecting a booster

battery� Use proper polarity in order to prevent sparks�

To jump start (negative grounded battery):

1� Shield eyes�

2� Connect ends of one cable to positive (+) terminals

of bottom post on solenoid rst (A), then positive

post of booster battery� (B)�

3� Connect one end of other cable to negative (-) termi-

nal of booster battery (C)�

4� Connect other end of cable (D) to engine block on

unit being started�

To prevent damage to other electrical components on unit

being started, make certain that engine is at idle speed

before disconnecting jumper cables�

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7

Service

SERVICE CHART

Before servicing or making adjustments to the machine, stop engine, set park

break, block wheels and remove key from ignition�

Follow all procedures and ONLY use parts prescribed by the manufacturer�

Read the engine manual before maintenance�

The suggested maintenance checklist is not oered as a replacement for the manufacturer’s engine manual

but as a supplement� You must adhere to the guidelines established by the manufacturer for warranty cover-

age� In adverse conditions such as dirt, mud or extreme temperatures, maintenance should be more frequent�

Maintenance Service Interval Maintenance Procedure

Aer the rst 8 operating hours Torque the wheel lug nuts. (64-74 /lb (87-100 Nm))

Change the engine oil lter.

Before each use daily Check the engine oil level.

Clean area around muer and controls.

Check the hydraulic uid level.

Check the tire pressure.

Check condition of hydraulic hoses and ttings.

Inspect and clean the machine.

Aer the rst 50 hours Change Hydraulic Oil Filter.

Every 100 hours Clean or change air lter.1

Clean pre-cleaner.1

Change engine oil and lter.

Replace spark plug .

Lubricate machine.

Clean or change remote air cleaner.

Check the battery uid level and cable connections..

Check muer and spark arrestor.

Check belt tension .

Every 250 hours Check engine valve clearance and adjust if necessary.

Check idle speed.

Clean battery terminals.

Change hydraulic oil lter.

Torque the wheel lug nuts. (64-74 /lb (87-100 Nm))

Every 500 hours or yearly Change fuel lter.

Change hydraulic oil and lter.

Clean oil cooler ns.1

Clean air cooling system.1

Check safety lter in remote air cleaner.

1 In dusty conditions or when airborne debris is present, clean more oen.

8

Service

END USER’S SERVICE CHART

Duplicate this page for routine use.

Maintenance Check Item For the week of:

Mon Tues. Wed. urs. Fri. Sat. Sun.

Check the Safety Seat Switch

Check Steering Operation

Check the fuel level

Check the engine oil level.

Clean the air lter

Clean the engine cooling ns.

Check for unusual engine noises

Check the hydraulic oil level

Check hydraulic hoses and ttings for

damage

Check for uid leaks.

Check the tire pressure

Check the Instrumentation

Inspect electrical system for frayed wires

Check park brake adjustment

Change oil lter.

Change oil.

Lubricate Machine

Ensure all warning decals are intact.

Areas of Concern

Inspection Performed by:

Item Date Information

9

Service

ADJUSTMENTS

RAKE LIFT CYLINDER

Completely lower Rake Lift� Remove the clevis pin (A)� Twist lift

linkage (C) so clevis pin end of cylinder extension lines up with

holes in attachment lift arm (B)� Replace clevis and cotter pins�

Tighten Jam Nut (D)� Raise and lower Rake Lift to check for

proper clearance�

Tighten until there is sucient tension between lift arm and

quick hitch and will not move in full up position�

When the rear rake attachment is

lowered while the machine is in

forward motion, the forward speed

of the machine will slow drastical-

ly� Operator should be prepared for

a rapid change in speed�

PARK BRAKE

The park brake is located on the left hand side of the

machine and operates both rear wheels� Pull lever back

to engage and push forward to disengage�

To adjust, turn the knob on the end of the handle�

DRUM BRAKE ADJUSTMENT

The brake can be adjusted through the access hole in

the backing plate� Remove the rubber plug from the

backing plate� Using a drum brake adjusting tool, or a

suitable at blade screw driver, rotate the adjusting star

towards the axle shaft to expand the shoes,one click at

a time� Expand the shoes until slight contact is made with the drum� It is highly recommended that you adjust

1 click at a time with the maximum adjustment being 2 clicks� Rotate the drum back and forth to insure the

brake is not rubbing excessively, if so back o the adjuster star. Slight rubbing is acceptable as the brake is

used it will seat in� Test after each adjustment�

10

Service

ADJUSTMENTS

WHEEL ‘CREEP’ ADJUSTMENT

‘Creep’ is when engine is running and hydrostatic transmission is in neutral, but due to inadequate alignment,

wheels still move� Do the following procedures to stop

this motion�

1. Lift up and support machine so all wheels are o

the ground and can turn freely�

2� On the top of the pump there is a Creep Arm�

Loosen bolts�

3� With engine running adjust the creep arm side to

side in slot so centering arm centers on the swash

plate�

4� Tighten all fasteners and test by using foot pedal

linkage to see that the "creep" is removed�

5. Turn engine o and lower machine.

TO ADJUST FOOT PEDAL THROTTLE CABLE

1. Jack up unit so that all drive wheel are o the

ground� (Use jack stands)

2� Start the engine, make certain that the hand throt-

tle is in the idle position (1200 engine RPM)�

3� Engine speed must increase as soon as the foot

pedal begins to move in either direction� At the full

forward position, the engine RPM must be 3600

RPM ± 100�

4� Minor adjustment can be made by backing out

(unscrewing) Retainer (Ref A) until you reach full

engine RPM with the foot pedal fully depressed in the forward position� Be sure to recheck after the

nuts are fully tightened�

5� Major adjustment needs to be made by pulling the slack out of the cable� Loosen the screw in the wire

block on the engine that is clamped onto the end of the cable and sliding it up to the cable block that is

through the throttle plate� Do not let the throttle plate move to increase idle speed� Tighten the screw�

6� Test run to determine that there is no binding and that engine idle speed is 1200 RPM and that it is

3600 RPM at full forward position of the foot pedal�

11

Service

ADJUSTMENTS

SPEED BOSS

Speed Boss allows the machine to operate at

a proper speed while raking sand traps on golf

courses� This speed boss has been factory set at

an average speed of 3-4 m�p�h� (5-6�5 kph)� The

Speed Boss will only limit the speed while the

rake is lowered into the operating position� The

speed setting may be adjusted by turning the

Ball Joint (A) counterclockwise to make the ma-

chine operate slower or turn clockwise to go fast-

er� Tighten jam nut� Check to make sure nothing

is binding and test drive to check desired speed�

For RBS System, Spiker and Grader Box remove

the speed boss arm and the speed boss rod from

machine so it does not interfere with other opera-

tions�

STORAGE

When storing, remove the key from the key switch to avoid unauthorized persons from operating machine�

1� Before storing clean machine thoroughly�

2� Check bolts and nuts, tighten as necessary�

3� Make all repairs that are needed and remove any debris�

4� Remove the battery, adjust the electrolyte level and recharge it� Store the battery in a dry, dark place�

5� Store in a clean and dry area, but NOT near a stove, furnace or water heater which uses a pilot light or

any device that can create a spark�

6� Engines stored over 30 days need to be protected or drained of fuel to prevent gum from forming in a

fuel system or on essential carburetor parts� Check the engine manual and follow the instructions for

the storage of the engine�

12

Diagrams

Color Code Chart

Bl Blue

Br Brown

Y Yellow

Grn Green

O Orange

R Red

B Black

P Purple

W White

WIRING DRAWING

13

Diagrams

WIRING PARTS LIST

REF # PART # DESCRIPTION QUANTITY

1 12-804 Hour Meter 1

2* 42-118 Electric On-O Valve 1

42-118-01 Coil 1

3* 2WD/3WD Switch

15-725 Mount Panel End 1

15-726 Switch Body Light 1

15-731 Actuator Amber 1

4 Lights Switch (Optional)

15-729 Mount Panel Middle 1

15-727 Switch Actuator, no light 1

15-782 Rocker Switch, Unlit 1

5 34-201 Lights (Optional) 3

43-505 Lights Wire Harness 1

6 13-488 Ignition Switch 1

7 8975 Circuit Breaker, 30AMP 1

8977 Breaker Boot 1

8 45-119 Red Battery Cable 1

9 Battery (not included) 1

10 22-065 Black Battery Cable 1

11 13-750 Starter Solenoid w/ Connector 1

12 43-024 18hp Briggs & Stratton 1

15-165 16hp Briggs & Stratton 1

13 14-292 Seat Switch 1

14 50-359 Warning Indicator Lights 1

15 22-017 Starter Cable 1

45-042 Wire Harness 1

* For Sand Star II and III only (45-002 and 45-003)

14

Diagrams

45-204 HYDRAULIC DRAWING

15

Diagrams

45-204 HYDRAULIC PARTS LIST

REF # PART # DESCRIPTION QUANTITY

1 45-024 Hydraulic Hose 37�5" 1

2 45-136 Hydraulic Hose 24" 1

3 45-025 Hydraulic Hose 29" 1

4 45-023 Hydraulic Hose 45" 1

5 34-103 Orbitrol 1

6 45-027 Hydraulic Hose 40" 1

7 45-028 Hydraulic Hose 21�5" 1

8 13-729 2-Bank Hydraulic Valve 1

9 45-030 Hydraulic Hose 47" 1

10 45-032 Hydraulic Hose 17�5" 1

11 45-029 Hydraulic Hose 27" 1

12 10-554 Steering Cylinder 2

18-154 Rod End 2

13 45-031 Hydraulic Hose 50" 1

14 43-150 Rake Cylinder 1

42-040 Yoke End 1

15 76-238 Front Wheel Motor 1

16 45-187 Hydraulic Hose 70" 1

17 45-186 Hydraulic Hose 58" 1

18 42-797 Hydrostatic Pump 1

19 45-037 Hydraulic Hose 12�5" 1

20 18-170 Tee 2

21 45-041 Right Upper Steel Tube 1

22 45-040 Right Lower Steel Tube 1

23 45-065 Right Wheel Motor w/ Brake 1

24 45-066 Left Wheel Motor w/ Brake 1

25 45-039 Left Upper Steel Tube 1

26 45-038 Left Lower Steel Tube 1

27 8832-37

3

/

4

" Suction Hose x 37" 1

18-040 Hose Clamp 2

28 45-036 Hydraulic Hose 35�5" 1

29 45-109 Hydraulic Hose 52�5" 1

30 42-005 Oil Tank 1

13-747 Filler Breather 1

31 23-006 Oil Filter 1

23-031 Replacement Filter only 1

32 34-105 Cooler 1

HYDRAULIC PRESSURES

Pump Displacement �913 in

3

/rev Charge Pump Displacement �33 in

3

/rev

Pump Input Speed (up to) 3600 rpm Max� Inlet Vacuum 5 in� Hg

Max� Operating Pressure 3000 peak psi Max� Case Pressure 25 psi

Implement Setting 700-1000 psi Relief Valve Pressure (set at) 3000 psi

13-729 Hydraulic Valve (2 bank) 900 psi

16

Parts

MAIN FRAME DRAWING

17

Parts

MAIN PARTS LIST

REF# PART# DESCRIPTION QUANTITY

1 HNL-12-20 Lug Nuts

1

/

2

- 20 10

2 14-265 Axle Nut (part of wheel motor) 3

3 45-021 Knobby Tire and Wheel 3

45-021-01 Tire 22 x 11 - 10 3

45-021-02 Wheel 3

4 42-833 Fuel Tank 1

5 15-781 Cup Holder 1

6 45-123 Rake Holder 1

7 45-043 RH Fender 1

8803-11 Black Trim 11" 1

8 8-532 Crate 1

9 42-834 Air Cleaner 1

42-834-01 Band 1

42-834-02 Hood 1

42-834-03 Safety Filter 1

42-076-03 Replacement Filter 1

10 60-106 Park Brake Lever 1

11 8959-26 Flex Hose 1

18-116 Hose Clamp 2

12 13-747 Filler Breather 1

13-586-03 Neck 1

13 42-005 Oil Tank 1

14 45-044 LH Fender 1

15 13-718 Steering Wheel 1

13-726 Center Cap 1

16 76-364 90° Black Boot (comes with 76-362) 1

76-362 Tilt Steering Mechanism 1

17 45-026 Nose Cone 1

8803-45 Black Trim 45" 1

18 45-047 Foot Rest Plate 1

45-132 Foot Rest Grip 1

19 45-099 LH Floorboard 1

45-064 LH Floor Mat 1

20 45-022 Molded Foot Pedal 2

21 45-098 RH Floorboard 1

45-063 RH Floor Mat 1

22 45-145 Floorboard Frame 1

23 45-085 Seat Panel 1

24 14-269 Adjustable Low Back Seat 1

25 45-050 Main Frame 1

26 42-814-02 Fuel Cap 1

27 18-436 Lock Hole Plug 1

OPTIONAL TURF TIRES

48-265 Tire & Wheel 3

43-123-01 Turf Tires 5 psi (�34 bar) 3

16-857-02 Wheel 23-10�50 x 12 3

18

Parts

SEAT PANEL DRAWING

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Smithco Sand Star IV Owner's manual

Smithco Sand Star IV Owner's manual

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